Continuously operable multi-deck hopper



1962 J. M. CUNNINGHAM ETAL 3,062,535

CONTINUOUSLY OPERABLE MULTI-DECK HOPPER 3 Sheets-Sheet 1 Filed Aug. 19, 1960 mW k i 4 0- g INVENTORS JAMES M. CUNN'NGHAM FRANCIS L. PRATT By 424., z

FIG. 2c

, TQ E Nov. 6, 196 J. M. CUNNINGHAM ETAL 3,062,535

CONTINUOUSLY OPERABLE MULTI-DECK HOPPER Filed Aug." 19, 1960 3 Sheets-Sheet 2 Nov. 6, 1962 J. M. CUNNINGHAM ETAL 3,062,535

CONTINUOUSLY OPERABLE MULTI-DECK HOPPER 3 Sheets-Sheet 5 Filed Aug. 19, 1960 E c R U 0 S M U U C A V FIG. 7

FIG. 6

United rates Patent Gfifice 3,062,535 Patented Nov. 6, 1962 3,062,535 CONTINUOUSLY ()PERABLE MULTI-DECK HOPPER James M. Cunningham and Francis L. Pratt, Endicott,

N.Y., assignors to International Business Machines Corporation, New York, N .Y., a corporation of New York Filed Aug. 19, 1960, Ser. No. 50,710 15 Claims. (Cl. 27162) This invention relates to movable hoppers and the like for presenting stacks of forms to a feeding mechanism for serial feeding to a transport system, and more particularly relates to an improved hopper having a plurality of movable decks and embodying means for automatically providing continuous presentation of forms from a stack on a succeeding deck whenever all forms have been fed from a stack on the preceding deck.

It is known to provide multiple deck hoppers comprising a plurality of loading plates or trays which carry stacks of forms of selectable height, and an elevating mechanism which automatically raises the effective plate (i.e., the plate containing the forms that are being taken by the feeding mechanism) as the forms are fed therefrom. It has also been proposed to provide manually operable means for elevating a succeeding plate so the top of the stack of forms carried by said plate will contact the underside of the effective plate; whereupon clutch means must be manually actuated to disconnect the effective plate from the automatic elevating mechanism and connect the succeeding plate thereto, and the efiective plate must be manually removed and any forms thereon manually transferred to the top of the stack on said succeeding plate. If, to avoid such manual transfer, the elevating mechanism is permitted to drive the effective plate through the medium of the succeeding plate and its pile of forms, damage to or wear of the feed mechanism could occur if the forms are exhausted and the bed of the effective plate is driven up into jamming contact with the feeding mechanism.

In these and other previously proposed arrangements, forms cannot automatically be presented continuously to the feeding mechanism. Also the operators attention and intervention is necessary at the critical time that the forms are about to b: exhausted from the efiective plate, in order to remove the effective plate to permit feeding to progress. Hence, the operator must stand by idly as such time approaches in order to prevent the feeding mechanism from being undesirably jammed by, or at the very best being idly engaged by, the platebed. In any event, if the operator is not present at the critical time, feeding will be suspended until he does intervene.

The principal object of this invention is to provide an improved multi-deck hopper wherein after all forms of a stack have been fed from one movable form-carrying deck member, forms can be fed automatically from the succeeding movable form-carrying deck member without interruption or intervention of an operator.

Another object is to provide an improved hopper of the above general type wherein the deck members successively move past the feeding mechanism and beyond a feed line or zone as and after all forms have been fed therefrom in order to permit feeding to progress automatically from the succeeding deck member without interruption or intervention of an operator, and wherein the hopper drive mechanism is stopped to stop movement of the members if more than a. predetermined number of such members is permitted to accumulate beyond the feed line or zone.

According to the invention, the hopper apparatus com- ;prises a plurality of removable deck members on which forms may be prestacked or stacked after insertion into the device. As forms are fed from the stack on one deck member, such member will be driven automatically toward the feed line or zone to maintain the forms in position to be fed by a feeding mechanism, such as a picker. Meanwhile, another deck member may be inserted and, if desired, loaded while inserted. Upon a manual signal from the operator, the other deck member will be driven automatically until the nearest form presses against the adjacent side of the deck member, whereupon the members will move up substantially in unison until all forms have been fed from said one member. The one member will then be driven beyond the feed line or zone, while the feeding mechanism will automatically without interruption begin feeding forms from the other member, because the feeding mechanism can work through a recess provided in each member. The one member may be removed at any time thereafter for reloading and it or a third member inserted so as to succeed said other member, and feeding will thus progress automatically without interruption and without requiring intervention of the operator at any critical time. The operator need merely periodically remove the members at his convenience after they have passed the feed line so that they will not unduly accumulate.

The hopper apparatus also preferably, though not necessarily, comprises stop means for automatically stopping hopper operation if more than a predetermined number of deck members are permitted to accumulate beyond the feed line or zone. This assures automatic stoppage when conditions indicate that all forms in the hopper have been fed therefrom.

The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of a preferred embodiment of the invention, as illustrated in the accompanying drawings.

In the drawings:

FIG. 1 is a perspective view of a hopper device embodying the invention shown associated with a pair of picker type feeding mechanisms;

FIGS. 2A, 2B, 2C are enlarged end elevation views showing, under various conditions, corresponding positions of an entry switch shown in FIG. 1;

FIG. 3 is an isometric view of a drive mechanism only partially shown in FIG. 1;

FIG. 4 is an enlarged perspective view of a lower deck level contact and the mechanical control mechanism therefor, shown generally in FIG. 1;

FIG. 5 is an enlarged view of a feed level contact and a vacuum control contact shown in FIG. 1;

FIG. 6 is an enlarged view of one of the stop switches and transfer switches shown in FIG. 1; and

FIG. 7 is a schematic view of the electrical circuit for the hopper device, including the various contacts and switches shown in the other figures.

Description As illustrated in FIG. 1, the hopper device embodying the invention comprises dissimilar deck members, such as flat plates 1, 2. Each plate carries a toggle-type actuator 3 and has vertically alignable recesses 4 extending inwardly from its rear edge. Plate 1 has three lug-like grips 5, two extending outwardly from one side edge of the plate near the ends thereof, and the other extending outwardly from the opposite side edge near the center thereof. These three grips 5 can removably interlockingly engage respective ribbed, upwardly movable belts 1a, 1b, 1c of a driving mechanism 6, when they are moved laterally into such engagement.

Plate 2 has similar grips 7 but arranged for engaging similar respective upwardly movable belts 2a, 2b, 20. These grips 7 and belts 2a, 2b, 2c are, however, arranged 3 reversely to the grips and belts 1a, 1b, 10, such that the belt 20 is disposed between belts la, 11), whereas the belt is disposed between the belts 2a, 2b. Thus, the belts and grips of the respective plates ll, 2 are triangularly arranged but with the apex of each such triangle at opposite side edges of the hopper.

As illustrated, the plates 1, 2 have respective pairs of recesses 8, 9 the recesses of each pair extending inwardly from the rear edge of the corresponding plate in straddling relation to the recess 4. However, the spaced recesses 8 of plate 1 are offset somewhat with respect to the corresponding recesses 9 of plate 2 such that only a portion of each recess in one plate is adapted to overlie a portion of the corresponding recess in the other plate. The overlying portions of the recesses 8, 9 provide two vertical cut-out paths through the plates to permit the plates 1, 2 to rise above the feed line or zone of a feeding mechanism which, as illustrated, comprises two oscillating type pickers ll). In other words, these overlying portions of the recesses 8, 9 provide sufficient lateral and front-to-rear clearance to permit the plate to move past the pickers 10 even when said pickers are oscillated the maximum degree toward the hopper.

In the embodiment illustrated, the pickers 1t can feed forms anywhere within a preselected feed zone, and the effective plate is drive only intermittently by the driving mechanism 6 as necessary to maintain said plate Within said zone. The maximum height of the feed zone is controlled by the degree of swing of the flexible cantilever contact arm of a feed level contact FL. Contact FL and a vacuum control contact V are vertically aligned above, and can project with clearance through, the recess 4 of each plate. Hence, these contacts FL, V will never be contacted by either plate 1 or 2. However, the contacts V, FL are adapted to engage and be controlled by the forms on the plates. Contact V is normally open and when engaged by a form or forms will close a circuit to actuate a vacuum solenoid VS to apply suction to the suction ports (not shown) opening through the picking surface of the pickers 10. Contact FL is normally closed and is opened by and when the top form on the effective plate is above a critical line. Upon being closed, contact FL sets up a circuit to cause driving mechanism 6 preferably to drive the effective plate somewhat above said critical line, thereby actually providing a feed zone within which the pickers 10 may effectively operate and eliminating the need for continuously operating the driving mechanism.

Transfer switches T1, T2 are respectively paired with stop switches S1, S2, the pair T2, S2 being best shown in FIG. 6. Switches T1, S1 are disposed so that plate 2 may pass upwardly beyond the feed line and zone without striking any part of these switches because of the clearance provided by the nonoverlying portion of one of the recesses 9. However, these switches T1, 81 are so disposed that plate 1 will strike the flexible arm of switch T1 when said plate moves a predetermined slight distance beyond the feed line and will strike the arm of switch S1 after said plate has moved up a predetermined greater distance beyond the feed line, for reasons hereinafter explained. On the other hand, transfer switch T2 and stop switch S2 are disposed so that they will project with clearance into the non-overlying portion of one of the recesses 8 of plate 1 and their flexible arms will be successively engaged only by plate 2 as it moves said predetermined slight distance and greater distance beyond the feed line. Each switch T1, T2, S1, S2 comprises a normally closed contact x and also a normally open contact y which is adapted to be closed only when the appropriate switch arm is deflected by contact with the proper type of plate.

Whenever the lower of the plates 1 or 2 is moved upward far enough for the forms on such lower plate to hit and spread the normally depending arms 15, 16 of the toggle actuator 3 carried by the upper plate, arm will be projected beyond the side edge of the upper plate. As arm 15 is projected, it will through its yoked end drive an offset crank 17 against the resistance of a bias spring 18 and swing a suitably insulated arm 19 clockwise for opening a normally closed lower deck level contact LDL. When the upper plate moves up from the lower plate a slight distance sufficient to enable enough contraction of the toggle arms 15, 16, contact LDL will be operatively reclosed by action of spring 18. While con tact LDL is closed, a circuit hereinafter described will be set up to cause the lower plate to be moved upwardly toward the upper plate until said contact is reopened.

Entry contacts El, E2 are provided on opposite sides of the hopper, such as adjacent the belts 1c and 20, as illustrated. These contacts E1, E2 respectively sense whether a plate of plate 1 configuration or a plate of plate 2 configuration has been entered at the entry point of the device. As best shown in FIGS. 2A, B, C, plate 1 is entered laterally into the hopper device (see FIG. 2A) so that one of the grips 5, in addition to interlocking with the drive belt 10, also strikes and moves an insulationsheathed finger 20 (see FIG. 2B). This movement of finger 2t} closes contact E1 and thereby closes a circuit whereby, under proper conditions, the plate will be driven upward by driving mechanism 6 until the grip 5 rides off the finger (see FIG. 2C).

In the embodiment illustrated, the driving mechanism 6 comprises electro-magnetic clutches 1d, 2d and other elements now to be described. Clutches 1d and 2d respectively control transmission of power from a suitable drive shaft (not shown) to respective worm shafts 21, 22 which are rotated at least a single revolution when their corresponding clutches are energized. As illustrated in FIG. 3, worm shaft 21 drives two worm wheels 23, 24, and shaft 22 drives two worm wheels 25, 26. Worm wheel 23 is keyed to an inner shaft 27 which drives belts in, 1b. Worm wheel 26 is rotatably mounted on shaft 27 but is keyed to a concentric tubular shaft 28 that encircles shaft 27 and drives belt 20. Conversely, worm wheel 25 is keyed to an inner shaft 29 that drives belts 2a 2b; and worm 24 is rotatably supported on shaft 29 but keyed to a tubular shaft 30 that encircles shaft 29 and drives belt 1c.

Thus, when entry contact E1 is closed by grip 5 of a plate 1, clutch 1d will normally be energized to cause said plate to be elevated until said clutch is deenergized by grip 5 riding off finger 20. During the period clutch id is energized, the entered plate 1 will be driven to a load position, in which it is shown in FIG. 2C, where it will stop upon deenergization of said clutch. Similarly, upon entry of a plate 2 into the hopper one of the grips 7 will close contact E2 and normally energize clutch 2d temporarily for driving said plate to load position.

As shown in FIG. 6, the electrical circuit controlled by these mechanically actuated elements V, FL, T, S, LDL and E includes relays R32, R33, R34, R35, R36, a posi tive line B and a negative line N. Each relay has a pick coil P, a hold coil H and contacts designated by lower case letters. All front contacts (open when the respecttive relay is deenergized) will be designated by unprimed letters, whereas all back contacts (closed with such relay energized) will be designated by primed letters. Where one contact arm or armature selectively controls a front contact and a back contact, such contacts will have the same letter but the back contact will have its letter primed for example, a back contact a of relay R32 will be designated at R3211.

Operation Assume initially that not plates 1 or 2 are entered in the hopper device; that the circuitry is therefore conditioned as shown in FIG. 7; and that a start switch SS is then closed to start a motor M which drives the drive shaft (not shown). Assume now that a plate of plate 2 configuration is to be entered first and then a plate of plate 1 configuration.

As best shown in FIGS. 1, 2 and 7, plate 2 is entered laterally to engage belts 2a, 2b, 2c and mechanically close contact E2. This closes a circuit between lines N and B via closed contact E2, back contact R36d, back contact R32a, clutch 2d and normally closed stop switch contact S2x, thus energizing clutch 2d to drive the plate 2 to load position as above described.

Meanwhile, a parallel circuit will be closed between lines N and E via back contacts R32a and R360! and pick coil P of relay R35, thus energizing said pick coil. With this pick coil R35P energized, a holding circuit will be established via front contact R3512, normally closed contact x of switch T2, and hold coil H of relay R35. Thus, once relay R35 is energized, it will be maintained energized via its holding circuit and independently of entry contact E2 to note and remember that a plate 2 has been entered.

With relay R35 energized, front contact R35d will be closed thereby setting up a circuit between lines N and B via front contact R3501, back contact R32d' and pick coil RSP for energizing relay R34. A holding circuit for relay R34 will then be established via front contact R351), switch contact T2x, front contact R34c and hold coil R34H to maintain relay R34 energized. Energization of relay R34 indicates that a plate 2 is the first one entered and insures that movement of plate 2 (rather than a plate 1) will be controlled to the feed level contact FL.

Meanwhile, as soon as plate 2 has risen to load position (F16. 2C), plate 1 may, if desired, be laterally entered so as to interlock with belts 1a, 1b, 1c, and close contact E1. Since relay R35 is energized and relay R36 is deenergized, back contact R3511 and front contact R360 will be opened, thus for the time being preventing energization of clutch lid to prevent plate 1 from moving up and jamming into plate 2 at the load position. Plate 1 Will not move to load position until relay R36 is energized in consequence of the operator depressing a load key LK to advance plate 2 above load position, as will now be explained.

Forms may be prestacked on plate 2 or as will here be assumed may be stacked on the plate while at the load position. After plate 2 has been loaded with forms, the operator manually depresses the normally biased open load key LK closing a circuit between lines N and B through front contact R350 to pick coil R361 to energize relay R36. A holding circuit will then be immediately established for relay R36 through hold coil R36H, front contact R3611, and normally closed switch contact S2x. Hence, the operator may remove his hand from key LK.

With relays R34 and R36 energized, a circuit will be closed between lines N and B through normally closed contact FL, front contacts R344: and R3661, clutch 2d, and switch contact S2x to energize clutch 2d. With clutch-2d energized, plate 2 will be driven upward by belts 2a, 2b, 20. When the top of the stacked form-s, strikes and closes vacuum control contact V, vacuum will be supplied to the pickers from the vacuum solenoid VS, it being noted that these pickers will oscillate whenever the drive shaft (not shown) is rotating. The pickers 10 will start to feed forms off the top of plate 2. Plate 2 will continue to rise until the top form strikes and opens contact FL and thus causes deenergization of clutch 2d.

Meanwhile, forms may beadded to plate 1. Plate 1 will rise automatically to load position as soon as relay R36 is energized and establishes a circuit through closed contact E1, back contact R33d, front contact R360, clutch 1d and switch contact Six to energize clutch 1d. A parallel circuit is also established via contact R360, back contact R33zr', to pick coil R32P to energize relay R32 and establish a holding circuit for relay R32 through front contact 32b, switch contact Tlx and hold coil R32H.

.Entry contact E1 is controlled in the samemanner as entry contact E2. Thus, when plate 1 has risen enough to disengage the contact El, this contact will resume its normally open position and open circuitry to deenergize clutch 1a and thus stop said plate at the load position.

When plate 1 has been loaded with forms, the normally biased open load key LK may again be manually depressed to closed position. Closure of key LK will close acircuit between lines N and B through key LK, front contact R32c of now energized relay R32, and pick coil R33? to energize relay R33. The operator may then release key LK because a holding circuit for relay R33 will immediately be established through its hold coil R33H, front contact R3312, and normally closed stop switch contact Sllx.

With relay R33 energized, a circuit will be closed between lines N and B through normally closed lower deck level contact LDL, front contact R34b of now energized relay R34, front contact R33a of energized relay R33, clutch 1a and closed stop switch contact Six to energize clutch 1d. With clutch 1d energized, plate 1 will rise until the forms spread the toggle actuator arms 15, 16 far enough for arm 15 to operatively turn offset crank 17 and thus open the lower deck level contact LDL; whereupon, clutch 1d will be deenergized to terminate upward movement of plate 1.

At this stage, the various components of the hopper device will be in the respective positions in which they are shown in FIG. 1. Contact V will be closed; contacts LDL and FL will be open, and switches T1, T2, S1, S2 will be positioned as shown in FIG. 6.

Meanwhile, forms will be fed from upper plate 2 by the pickers 1%). Whenever the level of the top form on plate 1 drops sufficiently to perm-it reclosure of the previously open feed level contact FL, clutch 2d will be reenergized to drive the plate 2 upward until the clutch is deenergized by opening of contact FL by pressure from the forms on plate 2. Since energization of the clutch 2d always desirably effects at least a single revolution of worm shaft 22, plate 2 will actually be driven to an upper limit of the feed zone, in which the contact FL is opened a degree corresponding to the thickness of a predetermined number of forms (not just a single form). This assures that the clutch 2d will not be energized each time one or two forms have been removed from the top of plate 2.

Thus, plate 2 will be elevated intermittently by successive closure and opening of contact FLv Meanwhile, as forms are fed from plate 2 and said plate rises intermittently, plate 2 will move away from plate 1. Whenever the distance between these plates increases enough to permit spring 18 to operatively collapse the toggle arms 15, 16 and effect reclosure of lower deck level contact LDL, clutch 1d will be reenergized through closed contact LDL, front contacts R34b and R33a of energized relays R34 and R33, clutch 1d and closed switch contact Slx. Thus, the plate 1 will rise substantially in unison with plate 2, although by a follow-up type movement rather than by a concurrent-type movement such as would be afforded if both plates were connected to a common drive so as to move upward together. This followup arrangement facilitates transfer of control of the feed level contact FL from the upper plate to the lower plate, as will be understood from the following.

It should here be recalled that the transfer switches T2, T1 and stop switch S2, S1 will not be contacted and hence will not be operated from their normal positions until corresponding plates 2, 1 have passed a predetermined slight distance and a predetermined greater distance above the upper limit of the feed zone. When the last form has been fed from the upper plate 2, the top form in plate 1 will be within the lower range of the feed zone, for the feed zone is of greater height or width than the thickness of each plate. The contact V will remain closed and contact FL will be closed in the manner now to be explained.

--the case of plate 1).

Referring to FIGS. 1 and 5, as soon as the last form is fed off plate 2, arm u of contact FL will flex downward partially into recess 4 in plate 2 and hit and be stopped by the stationary contact point p, thus closing contact FL; but the arm u will not drop far enough to hit the top of the forms on plate 1. However, the arm v of contact V will move down through recess and strike the top form on plate 1; and due to the inherent resiliency of the hitherto upwardly flexed flexible contact point 7 of the contact V, said point 1 will follow such movement and maintain contact with arm v through a limited distance but sufiicient to maintain contact V closed.

It should be noted that, during the initial ascent of plate 2, the top form on said plate hit arm v of contact V and drove arm v up into contact with flexible contact point f to close contact V; and the plate 2 continued to rise until contact FL was opened by the forms pushing arm u away from contact point p. Hence, this vertical range between initial closure of contact V and opening of contact FL provides the lower range of the feed zone throughout which range contact V remains closed.

With contacts V and FL closed in the manner just explained, vacuum will continue to be applied to the pickers 1f the pickers will without interruption start feeding forms from plate 1 because the pickers can work through the recesses 9 of plate 2; and plate 2 will rise the predetermined slight distance above the upper limit of the feed zone until the top form on lower plate 1 forces arm u away from contact point p and thus opens feed level contact FL. By this time, the upper plate 2 will have hit and moved arm t of transfer switch T2 to open switch contact T2x and close switch contact T23 The opening of switch contact T2x opens the relay R35 holding circuit R35b, TZx, R35H. This deenergizes relay R35 to establish a bypass circuit to clutch 2d through back contact R351), front contact R35'a of then energized relay R36, clutch 2d and the still closed stop switch contact 82x. Thus, plate 2 will continue to rise despite intervening opening of the contact FL because clutch 2d will be maintained energized via the just described bypass circuit and independently of contact FL. Plate 2 will rise until it strikes and moves arm s of stop switch S2 to open switch contact 82x and close switch contact 82y. Opening of contact 82x opens the relay R36 holding circuit R36H, R3611, SZx, to deenergize relay R36. Whenever convenient, the unloaded plate 2 may now be withdrawn from the device; it need not be withdrawn immediately. Since the device is not interested in unloaded plates which are above the feed zone and stopped by closure of switch contact 52y (or Sly), the relays R35, R36 become deenergized to disregard or forget their presence. These relays R35, R36 will be reenergized only if and after a plate 2 is entered at the entry point and closes switch E2.

Meanwhile, the opening of switch contact T2x will open the relay R34 holding circuit R340, T2x, R351) to deenergize relay R34. With relay R34 deenergizcd, the contacts FL and LDL will now be controlled through back contacts R34a', and R34b', respectively, to transfer control of the contacts FL, LDL such that contact FL will now be controlled by the new effective plate 1 and contact LDL will be controlled by a plate of plate 2 configuration if and when such is entered into the device to close entry contact E2.

From the foregoing, it will be apparent that relays R35, R36 are energized whenever plate 2 is the effective plate, and that relay R34 is energized to sense and remember that a plate of plate 2 configuration is the effective plate. The term effective plate refers to the plate which controls contacts V and FL, and hence is the upper plate until it passes beyond the upper limit of the feed zone and opens switch contact 52x (or Slx, in

On the other hand, the term succeeding plate refers to that which controls the lower deck level contact LDL. The relay R34 is deenergized or prevented from becoming energized to note and remember that a plate of plate 1 configuration is the effective plate. Relays R32 and R33 perform the same respective functions with respect to plate 1 as relays R35, R36 do with respect to plate 2. Hence, operation when a plate 1 is first inserted will now be only briefly described.

When plate 1 is entered into the device and closes entry contact E1, a circuit will be established between lines N and B through back contact R33d, and thence through back contact R3541 (if plate 1 is the only plate as just assumed, or a plate 2 has hit transfer switch T2 and deenergized relay R35) or alternatively through front contact R360 (if a plate 2 is below stop switch S2 and relays R35, R36 are thus energized) and then to clutch id and closed switch contact Six to energize clutch 1d. Plate 1 will rise until contact E1 opens and deenergizes clutch 1d. Meanwhile, a parallel circuit from R3512 (or R360) through back contact R3301 to pick coil R32P energizes relay R32. A holding circuit for relay R32 is then established through front contact R32b, switch contact Tlx, and hold coil R32P. Energized relay R32 will remember that a plate 1 has been entered.

With relay R32 energized, back contact R32d' will be opened making it impossible to energize relay R34. This insures that plate 1 will be under control of contact FL, if it has not already been placed under control of such contact by operation of transfer switch S2 in the manner above described.

After plate 1 has stopped at load position due to deenergization of clutch 1d following opening of entry contact E1, the plate can be loaded with forms. Then load key LK is depressed, closing a circuit through front contact R320 to pick coil R33P to energize relay R33. Relay R33 establishes its own holding circuit through hold coil R33H, front contact R331) and switch contact 51x. Energization of relay R33 now makes it possible for a plate 2, if any, entered below this plate 1 to rise to load position.

When plate 1 is the first plate, it will rise because contact FL will be closed and complete a circuit through back contact R3411, front contact R33zz of energized relay R33, clutch 1d and stop switch contact Slx to energize clutch 1d. Clutch 1d will remain energized and elevate plate 1 until the top form successively closes contact V and starts the vacuum to the pickers 1t) and then later closes contact FL and deenergizes clutch 1d. Plate 1 will then be elevated intermittently as the level of the top form drops enough to temporarily reclose contact FL and thus temporarily energize clutch 1d. After the last form is fed from plate 1, contacts V and FL will sense this. Contact V will remain closed and contact FL will close, as already more fully explained. Plate 1 will rise and hit transfer switch T1, opening contact Tlx and closing contact Tly. Opening of contact Tlx opens the relay R32 holding circuit to deenergize relay R32. This establishes a circuit to clutch 1d through back contact R32b, front contact R3311 of still energized relay R33, and still closed switch contacts Slx. So plate 1 continues to rise until it hits stop switch S1, opening contact Six and closing contact Sly. Opening of contact Slx destroys the holding circuit for relay R33.

Meanwhile, assuming that a plate 2 has been entered below plate 1, relay 35 will have been energized as soon as load key LK was depressed. Hence, as soon as relay R32 becomes deenergized, a circuit is established through front contact R35d, back contact R32d to pick coil R34P to energize relay R34. Relay R34 establishes its own holding circuit through front contact R340, switch contact T2x and front contact R351). When relay R34 is energized, contact FL will be placed under control of the entered upper plate 2, via front contact R3421, and contact LDL will be placed under control of an entered lower plate 1, if any, via front contact R3412.

Meanwhile, if a plate 2 has been entered below the first entered plate 1, it will close entry contact E2 and energize and hold relay R35, and then rise in the manner already explained to load position provided relay R33 is energized. After load key LK is depressed, a circuit will be established via front contact R350 to pick coil R36P to energize relay R36 which will hold through R361) and stop switch contact 82x. Clutch 2:! will now be energized through contact LDL, back contact R34b', front contact R36a, clutch 2d, and switch contact SZx. Plate 2 will rise until contact LDL is opened by the toggle actuator arm 15 carried at the bottom of preceding plate 1 and deenergizes clutch 2d. Plate 2 will rise intermittently to follow up movement of plate 1.

Transfer of control from plate 2 to plate 1 will be as just described in connection with movement of plate 1 successively into contact with switches Ti and S1.

From this description of a full cycle of operation based upon initial entry of a plate of plate 2 configuration and one of plate 1 configuration and follow-up movement and transfer of control to a plate of the other configuration, it will be seen that the device operates equally well no matter which type of plate is first entered into the device.

An interlock is provided to prevent entry of a plate at its entry station E1 or E2 from effecting energization of its corresponding clutch id or 2d and thus moving the plate to load position, if there should be another plate of the same configuration below its stop switch S1 or S2. If clutch 1d or 2d were permitted to become energized under this condition, it would drive up both plates of the corresponding configuration and thus could jam the upper plate into the pickers 10 if it is in the feed zone at the time the lower plate of the same configuration is entered. This interlock is provided by back contacts R33d and R3603. From the time a plate 1 leaves the load station (after load key LK is closed) and until it hits stop switch S1 and opens contact Six, back contact R33d' will be opened. Hence, if a plate 1 is entered and closes switch E1 at a time when another plate 1 is ahead of it, cnergization of clutch 10. will be prevented via opened contact R3311." until after said other plate hits the stop switch S1 and effects deenergization of relay R33; whereupon, the lower plate 1 will immediately advance to load position. Contact R36d will act in similar fashion to prevent concurrent movement of two plates 2.

Assume now that an unloaded plate has advanced into contact with its corresponding stop switch S2 or S1, thus closing contact 52y or Sly, respectively; that all forms have been fed from the following plate; and the latter has advanced into contact with transfer switch T1 or T2 thus closing switch contact T2y or Tly, respectively.

As shown in FIG. 7, concurrent closure of switch contacts Tly and SZy, or alternatively of switch contacts T2y and Sly, will complete one or the other of two two parallel branches of a stop circuit. This circuit may, for example, comprise a normally deenergized relay RS which has a back contact 5' that is interposed in series in the start circuit that includes start switch SS and the motor M. Motor M not only drives the drive shaft for the clutches 1d, 2d but oscillates the pickers and drives the rest of the form transport system (not shown because not forming part of the present invention). Thus, when relay RS is energized under the condition just assumed, it will open the start circuit and stop the motor M for shutting down the entire system.

This stop circuit prevents a lower plate from being undesirably jammed into an upper plate that has already actuated its stop switch, it being noted the lower plate would normally be driven up until it actuated its own stop switch. This stop circuit also desirably shuts down the entire system when all forms have been fed from the plates then entered in the hopper. It is thus unnecessary for the operator to stand by to shut down the motor M to prevent jamming of the plates or useless operation of the motor.

It will thus be seen that continuous operation of the hopper device can be obtained without intervention of the operator at any critical time. Plates of forms may be entered, loaded, and then withdrawn at will after all forms have been fed therefrom. However, a stop circuit is preferably provided to stop the entire system including the hopper device if more than a predetermined number of unloaded plates should accumulate above the feed zone and thus indicate that there are not more forms to be fed from the hopper device.

It will be understood that contact V can readily be eliminated if the vacuum control feature is not desired or if a non-vacuum type picker mechanism is used. Also instead of the recesses 8, 9 being partially offset, they may be aligned, and one of the grips 5 and 7 used to actuate the switches T1, S1 and T2, S2, respectively.

While the invention has been particularly shown and described with reference to a preferred embodiment thereof, it will be understood by those skilled in the art that the foregoing and other changes in form and details may be made therein without departing from the spirit and scope of the invention.

What is claimed is:

1. A hopper device for advancing a series of stacks of forms to a feeding mechanism which feeds forms successively off the stacks, said device comprising, in combination, members of at least two different configurations carrying stacks of forms and arranged alternatively so that members of differing configurations will be successively presented to the mechanism, means including drive means for moving the members successively toward and beyond the feeding mechanism, and means operative upon movement of any member to a certain point beyond the feeding mechanism to disengage such member from the drive means to prevent it from being driven beyond such point, the last introduced means including a plurality of indentical means each mechanically actuated only by members of a particular configuration so as to know which of said members is to be so disengaged.

2. A hopper device for advancing successive stacks of forms to a feeding mechanism of the type that feeds forms successively off the stacks, said device comprising a plurality of members of at least two different configurations removably insertable into the device sequentially at an entry station, a plurality of means each for driving the members of a corresponding configuration successively toward and then beyond the operating area of the mechanism as forms are fed thereby from one of the stacks, means normally conditioned upon entry of a member at the entry station to activate the corresponding driving means to move such member at least a limited distance toward the feed zone, and interlock means to prevent operation of the last-introduced means until after all forms have been fed from any preceding member of the same configuration, thereby to prevent undesired jamming of such preceding member against the feeding mechanism which could result from premature activation of said corresponding driving means.

3. The combination according to claim 2, wherein said members have recesses substantially aligned when they are within the device and providing clearance to permit the members to move beyond the feeding mechanism, and wherein the operating area of the mechanism is a zone rather than a line and is of sufficient width to permit the feeding mechanism to work through said recesses and feed forms continuously without interruption from the succeeding member as soon as all forms have been fed from the preceding member and before the latter is advanced beyond the feed zone.

4. A hopper device for advancing successive stacks of forms to a feeding mechanism of the type that feeds forms successively off the stacks, said device comprising a plurality of members of at least two different configurations removably insertable into the device sequentially at an entry station, a plurality of means each for driving the I, ll

members of a corresponding configuration successively toward and then beyond the operating area of the mechanism as forms are fed thereby from one the stacks, a plurality of means each for members of a difierent configuration and each normally conditioned upon entry of a member of proper configuration to activate the corresponding driving means to move such member to a load position, and means for preventing operation of the last-introduced means so long as a preceding member is at the load position.

5. The combination according to claim 4, including operator-conditioned means for activating the corresponding driving means of any member at the load position to cause it to be advanced therefrom toward the operating area, and means for deactivating the corresponding driving means whenever the forms on said any member substantially abut the preceding member, whereby as said preceding member moves toward the operating area said any member will keep pace therewith by a follow-up type movement.

6. The combination according to claim 5, wherein members of the different configurations are successively inserted in the device, and including feed level control means normally conditioned to cause said preceding member to advance toward the feeding mechanism as necessary to maintain the form to be fed within the operating area, means sensing which type configuration member is being controlled by said control means, and means controlled by said sensing means to prevent said control means from controlling members of any other configuration and also condition said deactivating means to control movement of a member only of such other configuration.

7. For use with a feeding mechanism of the type which feeds forms seriatim off successive stacks: a hopper device for advancing successive stacks of forms to the mechanism and comprising a plurality of members carrying respective stacks of forms, a plurality of drive means each for driving difierent members successively toward and then beyond the feed zone of the feeding mechanism; said members having recesses aligned with the feeding mechanism to permit the members to be driven beyond the feed zone and enable the feeding mechanism to feed forms from a succeeding member without interruption as soon as all forms have been fed from the preceding member and before such preceding member has been advanced beyond the feed zone; actuator means carried by each member and actuatable by pressure from the forms on a succeeding member, means normally conditioned to cause said succeeding member to be advanced by its drive means and abnormally conditioned upon actuation of the actuator means of the preceding member to disconnect said succeeding member from its drive means until the preceding member advances, feed level control means controlled by the level of forms on the preceding member to cause the latter to be driven by its drive means as necessary to maintain such level at least at a certain point within the feed zone and responsive to removal of all forms from such preceding member to cause movement of the latter beyond said feed zone, and means operable by and'upon movement of a member beyond the feed zone to effect a transfer of control whereby said control means will thenceforth control and be controlled by the level of forms on the next succeeding member.

8. The combination according to claim 7, including means other than said control means operable by and upon movement of a member a certain distance beyond the feed zone under control of said control means to drive such member a further distance beyond the feed zone independently of said control means to prevent it from being hit by the succeeding member when it is subsequently advanced said certain distance beyond the feed zone by said control means.

9. The combination according to claim 7, wherein said members are removably insertable into the hopper device,

and including means operable if a predetermined number of unremoved unloaded members accumulates beyond the feed zone to prevent operation of all of said drive means.

10. The combination according to claim 7, wherein said members are removably insertable into the hopper device, and including means responsive to entry of one member at an entry station to normally automatically advance such member to a load station, and interlock means conditioned by the presence of a preceding mem- 'er at the load station to prevent such operation of the entry-responsive means until such preceding member has moved beyond the load station and becomes controlled by the actuator-controlled means.

1. The combination according to claim 10, including means manually conditionable to place a member at the load station under control of said actuator-controlled means.

12. For use with a feeding mechanism of the type which feeds forms seriatim off successive stacks: a hopper device for advancing successive stacks of forms to the mechanism and comprising a plurality of members carrying respective stacks of forms, a plurality of drive means each for driving different members successively toward and then beyond the feed zone of the feeding mechanism, said members having recesses aligned with the feeding mechanism to permit the members to be driven beyond the feed zone and enable the feeding mechanism to feed forms from a succeeding member without interruption as soon as all forms have been fed from the preceding member and before such preceding member has been advanced beyond the feed zone; actuator means carried by each member and actuatable by pressure from the forms on a succeeding member, means normally conditioned to cause said succeeding member to be advanced by its drive means and abnormally conditioned upon actuation of the actuator means of the preceding member to disconnect said succeeding member from its drive means until the preceding member advances, feed level control means controlled by the level of forms on the preceding member to cause the latter to be driven by its drive means as necessary to maintain such level at least at a certain point within the feed zone and responsive to removal of all forms from such preceding member to cause movement of the latter beyond said feed zone, means operable by and upon movement of a member a certain distance beyond the feed zone under control of said control means to remove the last-mentioned member from such control and subject the succeeding member to control by said control means, means operable upon movement of said last-mentioned member said certain distance to cause such member to be moved further from the feed zone independently of said control means, means operable by and upon a chosen degree of such further movement to terminate such further movement, and interlock means operable if one member has been moved said chosen degree to stop the next succeeding member when it has been moved said certain distance thereby to prevent collision of said members.

13. For use with at least one feeding mechanism of the type which feeds forms seriatim ofi successive stacks advanced into a feed Zone: a hopper device for advancing successive stacks of forms to each mechanism and comprising a plurality of members carrying respective stacks of forms, said members being of at least two different configurations and arranged alternatively so that forms on members of differing configurations will be successively presented to each such feeding mchanism; a plurality of drive means each for driving members of a respective one of said configurations successively toward and then beyond the feed zone of each feeding mechanism; clutch means controlling selective operation of each drive means so the members may be advanced selectively and concurrently; said members having recesses aligned with each feeding mechanism to permit the members to move beyond the feed zone and enable each feeding mechanism to feed forms from a succeeding member without interruption as soon as all forms have been fed from the preceding member and before such preceding member has been advanced beyond the feed zone; actuator means carried by each member and actuatable by pressure from the forms on a succeeding member; means normally conditioned to permit said succeeding member to advance and abnormally conditioned upon actuation of the actuator means of the preceding member to disengage the clutch means for said succeeding member until the preceding member advances; feed level control means controlled by the level of forms on the preceding member to effect engagement of the clutch means of such member to move the latter as necessary to maintain such level at least at a certain point within the feed zone and responsive to removal of all forms from such preceding member to cause movement of the latter beyond said feed zone; a plurality of means each engageable only by members of a particular one of said configurations upon their being moved beyond the feed zone and operative whenever so engaged to cause said control means to thenceforth control and be controlled by the level of forms on the succeeding member having a different configuration than its preceding member; and means controlled by the last introduced means to cause such preceding member to be advance further beyond the feed zone independently of said control means.

14. A form transport system comprising a plurality of removable members carrying respective stacks of forms, and a driving means for the system including driving mechanism for driving the members successively toward and beyond a feeding mechanism as forms are successively fed by the feeding mechanism from the respective members, characterized in that the members are of at least two different configurations, and by provision of a plurality of elements one for each configuration and each actuatable only when and so long as a member of the corresponding configuration is positioned beyond the feed- 14 ing mechanism, and means responsive to actuation of at least two of said elements to automatically shut down the driving means of the system, including the driving mechanism, whenever a predetermined number of such members is permitted to accumulate beyond the feeding mechanism.

15. A hopper device for advancing a series of stacks of forms continuously to a feed zone of a feeding mechanism of the type which feeds forms successively off the stacks, said device comprising, in combination, at least two members, each having a thickness less than the height of the feed zone and each carrying stacks of forms; driving means for moving one of the members toward the feed zone; means for moving the next succeeding member toward said one member at an overtaking rate of speed until the endmost form on said succeeding member contacts said one member, such that the distances between forms of adjacent stacks will be substantially equal to the thickness of the intervening members; and means automatically operative after such contact to effectively couple said succeeding member to the driving means for said one member such that each of said members will be advanced in unison successively toward and then beyond the feed zone as the forms are removed from the respective members, said members having recesses aligned with the feeding mechanism to permit the latter to feed forms continuously without interruption from a member then within one portion of the feed zone as soon as all forms have been fed from the immediately preceding member and before such preceding member has been advanced beyond the other portion of the feed zone.

References Cited in the file of this patent UNITED STATES PATENTS 673,892 Agnew May 14, 1901 888,343 Molyneux May 19, 1908 900,782 Richards Oct. 13, 1908 2,335,078 Osborn Nov. 23, 1943 2,549,364 Bobst Apr. 17, 1951 

